Apparatus and method for cold-proofing multiple dough pieces

ABSTRACT

An apparatus and method are disclosed that allows multiple pieces of frozen dough to proof without heat or added humidity. The apparatus comprises a metal enclosure, devices to support trays of dough, and doors that allow access to the dough and to selectively open or close the enclosure, such that in the closed position the doors substantially seal the apparatus. Within the enclosure, the frozen dough is thawed, proofed, and held for controlled time periods at controlled temperatures while placed in a refrigerated chamber. A particular step may be accelerated under heat.

RELATED APPLICATION DATA

[0001] The present Application is a Divisional Application of U.S.Non-Provisional application Ser. No. 09/929,882, entitled “Apparatus andMethod for Cold-Proofing Multiple Dough Pieces” and filed on 14 Aug.2001.

BACKGROUND OF THE INVENTION

[0002] This invention relates to the field of dough proofing in general,and in particular to an apparatus and method for cold-proofing orhot-proofing multiple pieces of dough.

[0003] Proofing refers to the leavening or raising of dough. Doughprepared by mixing flour, water, yeast, carbohydrates, and otheringredients leavens or rises through yeast growth and metabolism ofcarbohydrates. Yeast metabolism of carbohydrates produces carbondioxide, which causes the dough to expand, “proofing” the dough.

[0004] As noted in U.S. Pat. No. 4,674,402 issued to Raufeisen, proofingis a function of time, temperature, and humidity. U.S. Pat. No.4,792,456 issued to Katz discloses that faster proofing is preferredbecause it retards microbial growth, improves shelf life of the finishedproduct, and optimizes quality. Accordingly, U.S. Pat. No. 5,580,591issued to Cooley states that proofing is optimal at elevatedtemperatures, around 95° F., which increase yeast activity.

[0005] Along with elevated temperatures, humidity aids proofing bypreventing the dough from drying out. Controlling the level of humidityduring proofing was addressed in the past with devices using steamgenerators or humidifiers, which added heated water vapor to theinterior of the proofing device. Such devices are disclosed, forexample, in Raufeisen, U.S. Pat. No. 4,635,540 issued to Dowds, and U.S.Pat. No. 5,072,666 issued to Hullstrung. In addition to steamgenerators, Raufeisen and U.S. Pat. No. 4,023,476 issued to Burgessdisclose that such devices employed blowers or air heaters to circulatethe heated water vapor inside the device.

[0006] As acknowledged in Raufeisen, the use of such steam generators orhumidifiers caused problems with condensation and mineral depositswithin the generators, which adversely impacted steam generation andtherefore the level of humidity. Hullstrung also noted problems withmaintaining uniformity in the atmosphere within such proofing devices.And the use of dough proofed conventionally at elevated temperatures hasbeen limited by a short shelf life after proofing, about two to threehours, often resulting in wasted dough. Problems with proofingconditions have also been known to affect the quality of dough, yieldingdough of inconsistent or undesirable quality by drying out the doughsurface or impeding yeast growth, which affects the aroma, flavor, andtexture of the finished product.

[0007] Because of the need for elevated temperatures, moreover, proofinghas been accomplished in devices separate from those for other steps inpreparing dough for use in making the finished product. For example,Raufeisen discusses a process whereby the dough must be transferredbetween devices for thawing, proofing, and refrigerating, requiringintensive labor and effecting less than ideal conditions for doughdevelopment during exposure to ambient conditions.

[0008] In the past, dough proofing devices have been insulated, as notedin Raufeisen, and provided enclosed atmospheres of selected temperaturesand humidity levels, as noted in Hullstrung. As explained in Hullstrung,proofing devices consequently tended to be elaborate—necessitating notonly insulation, but as mentioned above, steam generators or humidifiersand blowers or air heaters—and their operation complicated.

[0009] Thus, there is a need for an apparatus or method for proofingdough that yields dough of consistent and desirable quality, preferablywith an extended shelf life. A need exists also for an apparatus ormethod that simplifies dough proofing, for example, by eliminating theuse of externally regulated humidity. Yet another need exists for anapparatus or method for cold-proofing multiple pieces of dough.

SUMMARY OF THE INVENTION

[0010] The present invention substantially overcomes the foregoingproblems and achieves an advance in the art by providing an enclosuredefining an enclosed volume in which multiple pieces of frozen dough canproof. To that end, the enclosure is adapted to carry multiple doughpieces. The enclosure is preferably thermally conductive and adapted tobe received by a thermally controlled chamber. In another aspect of theinvention the enclosure includes a door to provide access to enclosedvolume.

[0011] In another aspect of the invention, a method comprises the stepof thawing frozen dough at a temperature above 32° F. The method alsoincludes proofing the thawed dough at a temperature above 32° F. in asubstantially enclosed environment. The method further includes holdingthe proofed dough at a temperature above 32° F. in a substantiallyenclosed environment for up to 48 hours.

[0012] The following detailed description and drawings will aid inbetter understanding the objects, advantages, features, properties, andrelationships of the present invention. The description and drawings setforth an illustrative aspect of the invention and demonstrate thevarious ways in which the principles of the invention may be employed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In the drawings:

[0014]FIG. 1 is a perspective view of an exemplary enclosure forproofing dough, in accordance with an aspect of the present invention,shown with the doors removed;

[0015]FIG. 2 is an exploded perspective view of the enclosure of FIG. 1;and

[0016]FIG. 3 is a flow diagram representing exemplary steps incold-proofing multiple pieces of dough using the enclosure in accordancewith an aspect of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0017] To create an environment in which multiple pieces of dough 16 canproof, an aspect of the present invention provides an enclosure 1defining an enclosed volume 2. Protrusions 3 are located on the innersurface of the enclosure 1 for supporting trays 14, which may be slidinto the enclosure 1 and supported by the protrusions 3 or any type ofsupporting device, such as shelves. In an aspect of the presentinvention, the trays 14 are made of metal or other conductive materials.

[0018] As shown in FIG. 1, the enclosure 1 may comprise half cavities orvolumes created by an optional partition or middle shelf 4. As willbecome apparent, adding a partition 4 provides certain advantages byallowing flexibility in the number of dough pieces 16 that can beaccommodated by the apparatus.

[0019] More specifically, as shown in FIG. 2, the enclosure 1 maycomprise a top 5 and a bottom 6 connected by two side panels 7, 8 andfour doors 9, 10, 11, 12, where two doors 9, 10 or 11, 12 stacked end toend extend the length of a side panel, 7 or 8. The doors 9, 10, 11, 12allow access to the front and rear of volumes defined by the enclosure 1and may be operable in an open or closed position. While four doors areillustrated, any number of doors may be used.

[0020] To substantially prevent ventilation and enhance humidityretention, optional strips of elastic material or gaskets 13 may beattached to the edges of the side panels 7, 8 or doors 9, 10, 11, 12.The enclosure 1 may also incorporate wheel-mounting plates 14 and wheels15 for mobility. Any number of wheels or rollers may be attached to thebottom 6 to impart mobility to the enclosure 1. Further, no wheels arenecessary to practice the invention. Optional handles 16 may also easemovement of the enclosure 1.

[0021] Although FIGS. 1 and 2 illustrate the enclosure 1 as arectangular structure, other shapes may be used that are capable ofcreating an enclosure 1. In addition, the enclosure 1 may be adapted tocarry multiple dough pieces 16, which may be referred to as shells ordiscs, in a number of ways. The dough pieces 16, may be placed on trays14 that are supported by the protrusions 2 or any type of supportingdevice, such as shelves. In an aspect of the present invention, thetrays 14 are made of metal, but other materials can be used withoutdeparting from the invention.

[0022] To allow the temperature of the enclosure 1 to readily adapt tothat of the environment external to the enclosure 1, whetherrefrigerated or heated, the enclosure 1 comprises a thermally conductivematerial, such as stainless steel or aluminum. However, the enclosure 1may be comprised of numerous other conductive materials—includingplastic and metal composites. To proof dough 16, the enclosure 1 isplaced into a thermally controlled chamber (not shown). The thermallycontrolled chamber provides temperatures utilized in the proofing methodof the present invention that are above or below room temperature.

[0023] In a thermally controlled chamber, the doors 9, 10, 11, 12 of theenclosure 1 may be selectively fixed in an open position to allow theair of the chamber to flow through the enclosure 1. The doors 9, 10, 11,12 may also be set into a closed position to substantially seal theenclosure 1 and create an internal volume 3 with its own environment.The humidity within this environment may be regulated by adjusting theamount of dough or number of dough pieces placed into the enclosedvolume 3. This is a result of the moisture contained in the dough. Asthe dough thaws, frozen water molecules melt, which allows the water toevaporate from the dough, thereby releasing water vapors. Inside theenclosure 1, substantially sealed, the released water vapors generateand maintain a naturally humid environment.

[0024] In an aspect of the invention, as shown in FIG. 1, the partition4 of the enclosure 1 separates the enclosure 1 into two sections 20. Anynumber of sections 20 may be used by adding more partitions 4, althoughthe following description illustrates only two sections 20. When theenclosure 1 is used at half capacity, the two separate sections 3 ensureproper humidity for cold-proofing by providing the volumes of thesections 3 appropriate for fewer dough pieces. In essence, the partition4 allows for micro-environments for proofing dough, adding flexibilityto enclosure 1. Furthermore, the separate sections 3 preserve thequality of dough by limiting access—and the accompanying unwantedventilation—to one cavity at a time as the dough is accessed for removalfrom the enclosure 1. The enclosure 1 allows for consistentcold-proofing of multiple dough pieces 16, by thawing, proofing, andholding the dough 16 in a substantially constant environment.

[0025]FIG. 3 is a flow diagram illustrating the method of the invention.The dough preferably comprises a water activity level of betweenapproximately 0.929-0.999, as measured against the activity level ofwater itself, which is 1.000. This measurement refers to the amount ofmobilized water molecules in the dough. A high level of water activityensures that yeast remains active and viable at the temperaturespreferably used in the cold-proofing method of the present invention. Inone aspect of the invention, the dough formulation comprises a wateractivity level of between approximately 0.940-0.980.

[0026] Before beginning the method of the present invention, raw doughis prepared and divided into pieces, which may be optionally flattenedand shaped into shells or discs, although any other shapes may be usedto practice the invention. At step 315, the dough is quick-frozen at atemperature between approximately −40° and −60° F., and after freezingare held at approximately −10° F. At this temperature the yeast remainsinactive. The dough may then be transported to restaurants for proofing.To thaw the frozen dough and initiate yeast activity at step 320, one ormore, trays of frozen dough pieces may be stacked into the enclosure 1,for example, by placing the trays on the inner protrusions 2. Theenclosure 1 may then be placed into a thermally controlled chamber at atemperature above the freezing point of water, for example, betweenapproximately 35°-50° F. Alternatively, thawing may occur at atemperature between approximately 38°-40° F. The doors 9, 10, 11, 12 ofthe enclosure 1 may be left open to allow air flow around the dough,which shortens the time required to thaw the dough, although the doughpieces will also thaw if the doors 9, 10, 11, 12 are in a closedposition. The dough pieces may be thawed for about half a day.

[0027] At step 325, once the dough pieces thaw, the dough releasesmoisture. To create a substantially enclosed volume 2 for proofing, theapparatus doors 9, 10, 11, 12 are closed, naturally humidifying theenclosed environment. As the dough pieces continue to release moisture,the enclosure 1 retains the moisture and thereby maintains a humidenvironment. In an aspect of the invention, the proofing step ismaintained for about a day at a temperature between approximately35°-50° F. Proofing may also occur at a temperature betweenapproximately 38°-40° F.

[0028] At step 330, the proofed dough pieces are ready to be used inmaking a finished product and can be held in the environment with thedoors 9, 10, 11, 12 of the enclosure 1 closed. In particular, the doughcan be maintained at a temperature between approximately 35°-50° F. Inanother aspect of the invention, the temperature range is maintainedbetween approximately 36°-40° F. At the 36°-40° F. temperature range,the dough pieces last for an extended shelf life of about a day and ahalf to two days, thus minimizing waste. Specifically, dough held at atemperature of approximately 35° F. may have a shelf life of up to twodays. Generally, the shelf life decreases with increasing temperature.The cold-proofing method of the present invention also accommodates upto eight hours of access to the dough in the enclosure 1 withoutsubstantially compromising consistency of quality.

[0029] In a further aspect of this method for cold-proofing dough, theproofing may be accelerated in times of dough shortage or temperatureerror during any particular step. FIG. 3 illustrates how a step prior tothe holding in cold-proofing at step 330 may be expedited. Either thethawing at step 320 or proofing at step 325 may be accelerated byapplying heat to the dough. In an aspect of the present invention, theaccelerated thawing at step 340 or accelerated proofing at step 345 mayoccur with the doors 9, 10, 11, 12 of the enclosure closed at atemperature of approximately 80° F. for about 60-90 minutes, with thedough formulation dictating the optimal amount of time. Alternatively,the accelerated thawing at step 340 or the accelerated proofing at step345 can occur at a temperature between approximately 75°-90° F. forabout 50-120 minutes. Still further, the accelerated thawing at step 340or the accelerated proofing at step 345 can occur at a temperaturebetween approximately 40°-100° F. for 40-240 minutes.

[0030] To accelerate the thawing at step 340 or proofing at step 345, afirst enclosure 1 is initially placed—without any dough pieces and withthe doors 9, 10, 11, 12 in an open position—into the thermallycontrolled chamber and preheated for about 30-60 minutes. In an aspectof the present invention, the enclosure 1 may also be preheated forabout 40 minutes. Frozen or thawed dough pieces may then be loaded intothe preheated enclosure 1 and allowed to thaw or proof, respectively,with the apparatus doors 9, 10, 11, 12 closed. Following acceleratedthawing at step 340 or accelerated proofing at step 345, the doughpieces may be loaded into a second enclosure 1 that has been preset to atemperature specified for the next step. Cold-proofing may thereafterresume with the proofing step 325 or holding step 330, as appropriate.

[0031] The invention is not confined to the aspects herein illustratedand described, and embraces such variations and modifications as may bewithin the ordinary skill of the artisan in this trade and as comewithin the scope of the following claims.

What is claimed is:
 1. A method for proofing dough comprising the stepsof: thawing frozen dough at a first temperature above 32° F.; proofingthe thawed dough at a second temperature above 32° F. in a substantiallyenclosed environment; and holding the proofed dough at a thirdtemperature above 32° F. in a substantially enclosed environment.
 2. Themethod of claim 1, wherein the first temperature and the secondtemperature are approximately equal.
 3. The method of claim 1, whereinthe second temperature and the third temperature are approximatelyequal.
 4. The method of claim 1, wherein the first temperature comprisesa temperature between approximately 35°-50° F.
 5. The method of claim 4,wherein the first temperature comprises a temperature betweenapproximately 38°-40° F.
 6. The method of claim 1, wherein the thawingstep is maintained for up to approximately 12 hours.
 7. The method ofclaim 1, wherein the second temperature comprises a temperature betweenapproximately 35°-50° F.
 8. The method of claim 7, wherein the secondtemperature comprises a temperature between approximately 38°-40° F. 9.The method of claim 1, wherein the proofing step is maintained for up toapproximately 24 hours.
 10. The method of claim 1, wherein the thirdtemperature comprises a temperature between approximately 35°-50° F. 11.The method of claim 10, wherein the third temperature comprises atemperature between approximately 36°-40° F.
 12. The method of claim 1,wherein the holding step is maintained for up to approximately 40 hours.13. The method of claim 1, wherein the dough comprises a water activitylevel of between approximately 0.929-0.999.
 14. The method of claim 13,wherein the dough comprises a water activity level of betweenapproximately 0.940-0.980.
 15. A method for proofing dough comprisingthe steps of: accelerated thawing of frozen dough at a first temperaturebetween approximately 40°-100° F. for approximately 40-240 minutes in asubstantially enclosed environment; proofing thawed dough at a secondtemperature above 32° F. in a substantially enclosed environment; andholding proofed dough at a third temperature above 32° F. in asubstantially enclosed environment.
 16. The method of claim 15, whereinthe first temperature comprises a temperature between approximately75°-90° F.
 17. The method of claim 15, wherein the thawing step ismaintained for approximately 50-120 minutes.
 18. The method of claim 15,wherein the second temperature comprises a temperature betweenapproximately 35°-50° F.
 19. The method of claim 15, wherein theproofing step is maintained for up to approximately 24 hours.
 20. Themethod of claim 15, wherein the third temperature comprises atemperature between approximately 35°-50° F.
 21. The method of claim 15,wherein the holding step is maintained for up to approximately 40 hours.22. The method of claim 15, wherein the accelerated thawing comprisespresetting the temperature of the substantially enclosed environment tothe first temperature for approximately 30-60 minutes.
 23. The method ofclaim 22, wherein the frozen dough is placed into the substantiallyenclosed environment preset to the first temperature.
 24. The method ofclaim 15, wherein the proofing comprises presetting the temperature ofthe substantially enclosed environment to the second temperature. 25.The method of claim 24, wherein the thawed dough is placed into thesubstantially enclosed environment preset to the second temperature. 26.A method for proofing dough comprising the steps of: thawing frozendough at a first temperature above 32° F.; accelerated proofing ofthawed dough at a second temperature between approximately 40°-100° F.for approximately 40-240 minutes in a substantially enclosedenvironment; and holding proofed dough at a third temperature above 32°F. in a substantially enclosed environment.
 27. The method of claim 26,wherein the first temperature comprises a temperature betweenapproximately 35°-50° F.
 28. The method of claim 26, wherein the thawingstep is maintained for up to approximately 12 hours.
 29. The method ofclaim 26, wherein the second temperature comprises a temperature betweenapproximately 75°-90° F.
 30. The method of claim 26, wherein theproofing step is maintained for approximately 50-120 minutes.
 31. Themethod of claim 26, wherein the third temperature comprises atemperature between approximately 35°-50° F.
 32. The method of claim 26,wherein the holding step is maintained for up to approximately 40 hours.33 The method of claim 26, wherein the accelerated proofing comprisespresetting the temperature of the substantially enclosed environment tothe second temperature for approximately 30-60 minutes.
 34. The methodof claim 33, wherein the thawed dough is placed into the substantiallyenclosed environment preset to the second temperature.
 35. The method ofclaim 26, wherein the holding comprises presetting the temperature ofthe substantially enclosed environment to the third temperature.
 36. Themethod of claim 35, wherein the proofed dough is placed into thesubstantially enclosed environment preset to the third temperature.